I'm surprised there was already a hole - I would have expected glue only.

Have you thought about adding a reinforcing patch over the enlarged holes? 3 layers at 60 degrees each would help, and look something like a Parlee bottle cage fixing. I would hate to see a crack starting there. Personally I would have gone down the route of cutting the wiring harness to allow threading, or perhaps using alternative connectors rather than enlarging the holes to take connectors. I like soldering though Also I'd recommend getting some bulkhead grommets (car supply shop) so that you get a waterproof install.

Thanks for the support guys. My wife is working in the evenings and this project gives me some good time in the garage when the kids are asleep.

mrfish- I like the reinforcement idea a lot.

The Di2 internal wiring kit comes with grommets but I prefer the re-inforced solution and making it more permanent and waterproof.

The bosses are screwed on with a small standard flat head but were also glued/painted -so it took a little more elbow grease to get them off. The screws holding the bosses together were connected by a rod all the way through the frame. The actual hole once the boss was off was tiny.

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